Apparatus for molding rail-joint castings.



Eta-882,660. PATBNTED M R. 24, 1908.

J. H. ALLEN. APPARATUS FOR MOLDING RAIL JOINT GASTINGS.

APPLIOATIION FILED JAN. 31. 1 907.

2 SHEETS-SHEET 1.

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v No. 882,660.

' PATBNTED MAR. 24, 1908. J. H. ALLEN.

APPARATUS FOR MOLDING RAIL JOINTBASTINGS.

APPLICATION IILED JAN. 31. 1907.

2 SHEETS-SHEET 2.

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, UNITED STATES PATENT OFFICE.

JOHN H. ALLEN, OF NEW YORK, N. Y., ASSIGNOR TO THE RAIL JOINT COMPANY, OF NEW YORK, N. Y., A CORPORATION OF NEW YORK.

APPARATUS FOR MOLDING RAIL-JOINT CASTINGS.

Specification of Letters Patent.

Patented March 24, 1908.

Application filed January 31, 1907. Serial No. 355,177.

T 0 all whom it may concern:

Be it known that I, J OHN II. ALLEN, a citi zen of the United States, residing at New York city, in the county of New York and State of New York, have invented certain new and useful Improvements in Apparatus for Molding Rail-Joint Castings, of which the following is a specification.

This invention relates to the art of manufacturing rail joints, and more particularly to the manufacture of that class of rail joints known as step or compromise joints, which are employed to connect rails of different heights and sections so that the tops and sides of these dissimilar rails are supported in alinement.

' In the manufacture of rail joints of the step or compromise type, the joint bars 01' plates are generally made of steel or malleable iron castings and of a design and configuration corresponding to that of the rail sec tions to be united, so that the difference in height and section of the two rails iscompensated for. The ordinary processes for casting bars for step or compromise rail joints require considerable time and are more or less expensive, largely on account of the care which must be exercised in forming a sand mold of sufficient stability to safeguard and retain in position the unsupported, comparatively thin, projecting parts in the mold. To provide for these requisites, the ordinary molding processes for rail joint bars, particularly of the step or compromise type, involve an expensive form of mold which is usually baked as an entirety, whereas the present inventionbbviates that by a construction of mold which only requires the baking of a sand face carrying a relatively thin unsupported projection or projections for shaping the corresponding portions of the casting.

To this end the invention has in view a simple, practical, and effective apparatus for molding rail joint castings whereby a process of casting may be carried out in a rapid and economical manner, thus materially effecting a saving in time and expense of manufacture, while at the same time producing a better, cleaner, and stronger casting than can be made by the ordinary methods or molds.

With these and many other objects in view, which will readily appear as the nature of the invention is better understood, the same consists in the novel construction, combination, and arrangement of parts hereinafter more fully described, illustrated, and claimed.

The essential features of the invention involved in the means for forming a mold for irregular castings, such as the bars for rail joints, are necessarily susceptible to modification without departing from the scope of the invention, but the preferred means of carrying the same into effect are shown in the accompanying drawings, in which:

Figure 1 is a sectional View of a set-up sand mold embodying the present invention, and shown adapted for casting the oint bar of a compromise rail joint. Fig. 2 is a ers ective view of the male pattern emp oyec in forming one face of the mold. Fig. 3 is a similar view of the female pattern box for forming the baked sand face. Fig. 4 is a sectional view of the pattern box with the baked sand face filled therein. Fig. 5 is a detail. perspective view of a form of rail joint casting made by the herein described mold.

Like references designate corresponding parts in the several figures of the drawings.

The present invention is capable of general application for molding irregular castings, es pecially those having a different configuration upon the opposite sides or faces thereof, but as the same possesses special utility as an improvement in the means for casting rail joint bars of the step or compromise type, the invention is fully exemplified by the illus trated embodiment, shown in the drawings, which illustrates the invention in its appli cation to the manufacture of a rail joint bar.

In applying the improved invention to the manufacture of the specific form of rail oint casting shown in Fig. 5 of the drawings, it will be observed that this casting forms one of the angle bars of a step or compromise oint of the continuous type, which kind of joint essentially consists of opposite com lemental angle bars arranged in rights and efts, and each having a main splice bar portion 1, a bearing head 2 at the top edge of the splice bar portion, an integral foot flange 3 adapted to overlie the base flanges of the rails, and

base plate sections 4-4 formed integrally with the foot flange 3, and lying horizontally beneath said foot flange to form therewith an intervening flange recess or pocket adapted to receive the base flanges of the rails. In this class of joint bars, the rest faces of the rail supporting bases 44 for the separate process for making a casting of the form shown in Fig. 5 of the drawings, there is first made a male pattern 5 for thesurface constituting what may be termed the outside of the joint bar, and a female pattern or pattern box 6 for the surface constituting the inner side of the same casting. As shown in Fig. 2 of the drawings, the male pattern body is formed with what may be termed a pattern projection 7 having the exact-configuration of the outside or outside surface of the joint bar designated in its entirety by the reference character B in Fig. 5 of the drawings. That is, the pattern impression surface of the attern projection 7 follows the irregular outine of the outer side of the bearing head 2, the splice bar 1, the foot flange 3, and the base plate sections l l, of the bar or casting B, and said pattern projection also preferably includes offstanding bosses 8 having the exact configuration of the spiking lugs or flanges 9 of the joint bar casting B.

The pattern box 6 has formed in one side thereof what may be termed a shaping re cess 10 acting as a former for the insertible dry sand face 11 which is shaped therein. The wall of this recess 10 is given an irregular outline conforming exactly to the configuration of the top and inner side of the bearing head 2 of the joint bar casting, and to the exact configuration of the inner sides of the splice bar 1, the foot flange 3 and the base plate sections 4 4 of the casting. By reason of having this configuration, the wall of the recess 10 forms within the pattern box an angular pocket 12 corresponding to the configuration of the flange recess or pocket 5 of the casting, and shapes or forms therein a correspondingly shaped web or flange formation 13 on the dry sand face 11. In addition to the elements enumerated, the pattern box has formed in the base of its recess core print openings 14 which shape the bolt-hole core projections 15 offset integrally from one side of the dry sand face 11. Also, beyond the plane of the mold-wall shaping-portions of the recess 10, the latter is provided at opposhape therein the holding shoulders or heads 17 and 18 respectively at opposite sides of the dry sand face 11. These holding shoulders or heads 17 and 18 are designed to abut against the opposing green body-sand face 19 of the mold that is formed by carrying out the herein described process.

In forming the mold, the male pattern 5 is utilized to impress, upon the face of the green unbaked body-sand 19 of the mold, the configuration of the outside surface of the casting so that said face of the green body-sand,

shaped from the pattern 5, constitutes one face of the molding cavity 20 in the mold. To provide for forming the opposite face or wall of the molding cavity 20, and hence shaping the inside of the casting, the insertible dry sand face 11 is sha ed in the recess 10 of the pattern box, an then thoroughly baked, after which the said dry sand face is inserted in the mold directly against the green body-sand 19, and in such relation thereto that the irregular outline of the molding wall of the sand face 11 will match with the molding wall of the green sand face 19, and thereby complete the exact configuration of the casting to be poured. With the green sand face and baked face in their side by side matching relation, the web or flange projection 13 of the face 11 is the comparatively thin unsupported part of the mold, but by reason of being an integral part of the baked face the same possesses sufficient stability and strength to withstand the pouring operation. The bolt hole cores 15 of the face 11 project across the molding cavity20 into contact with the opposing wall of the green body-sand face 19 to provide for properly forming and locating the bolt holes in the joint bar or casting.

The green body-sand face 19 and the dry baked sand face 11 are the ordinary sand bac ng in any suitable form of flask F which may beutilized for the purpose.

From the foregoing it will be obvious that the distinctive feature of the invention resides in shaping one face of the molding cavity in the green unbaked body-sand from a male pattern of one side of the casting, then forming a relatively small and thin baked sand face in a female pattern box having a pattern contour of the other side of the casting, and finally forming a mold with the baked sand face and green body-sand face in juxtaposition.

I claim:

1. A sand mold having a green sand face for one wall of the molding cavity, and an inserted baked sand face arranged to form the entire opposite wall of said cavity.

2. A sand mold having a green sand face and an inserted baked sand face arranged in site sides thereof with angular seats 16 which 1 matching relation, and respectively forming pioperly backed with opposite differently shaped sides of the moldopposite differently shaped side of the same ing cavity. casting. 10 3. A sand mold having a green sand face In testimony whereof I hereunto aflix my for one Wall of the molding cavity provided signature in the presence of two Witnesses. 5 With a pattern impression of one side of the JOHN H. ALLEN.

casting, and a baked sand face arranged in Witnesses: matching relation to the green-body sand BENJ.VVOLHAUP'1ER.

face and having a pattern impression of the E. A. VANDEUSEN. 

